Brush, and a method of manufacturing of a brush

ABSTRACT

A brush that includes an intertwisted wire core defining a longitudinal axis, and a plurality of bristles secured within the intertwisted wire core, each of the plurality of bristles having opposed ends that extend radially away from the core, and at least some of the opposed ends of the plurality of bristles being split into a plurality of fragments.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to Provisional Patent Application No. 62/896,094, filed Sep. 5, 2019, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a method of manufacturing of a brush for applying a composition such as a cosmetic, a medicinal or a personal care composition. The composition may include a liquid, semi-liquid, creamy, paste-like or viscous material. More particularly, the present disclosure relates to a brush and its method of manufacturing in which tips of bristles of the brush are split into numerous fragments.

BACKGROUND

Despite variations in the shape and material composition of a plurality of bristles, a wire, and a plurality of contours of an application head of a brush, the brushes of the prior art have been substantially limited in their adaptability to different materials and application goals. As a result, a mascara user seeking to achieve combing and separating will need to use a first type of brush, for example a brush with stiffer bristles; and then use a second type of the brush for better application of the product, for example a brush with softer bristles. Users seeking to yet further refine the application and appearance of the applied mascara will still need to use another type of the brush.

Disadvantageously, purchasing multiple separate brushes to achieve varied application goals is expensive. Furthermore, storing and transporting a plurality of brushes can be awkward and cumbersome. As a result, many cosmetic users will forgo access to the brushes that they desire in favor of convenience and reduced expense.

In many brushes, the prior art approaches have not provided a brush with a combination of all the desirable features for a mascara brush. A soft bristle feel combined with bristle stiffness, while still providing both high mascara loading as well as good combing effect.

Further, in order to ensure satisfactory making up of the eyelashes using such a brush, it is necessary not only for the eyelashes to come into contact with the make-up product on the bristles of the application head of the brush, but also for the eyelashes to be touched by the tips of the bristles so as to smooth the product along the eyelashes.

Thermoplastic polymers have long been used to form brush bristles in a wide variety of configurations. To increase the effectiveness of these brushes, the tips of such bristles have been split or “feathered” to provide a soft bristle tip. In the past, however, various difficulties have been encountered in splitting the bristle tips.

In particular, various techniques have been used to split paintbrush bristles to improve painting performance. Such procedures have been particularly suited to paintbrush bristles because long splits which propagate along a large portion (up to one inch) are particularly desirable. With certain brushes, however, only splitting of the tips is desirable. For example, the length of a typical toothbrush bristle is about (or less than) one half inch. If splitting were to occur along a large portion of a toothbrush bristle, the bristles would not be sufficiently rigid to adequately clean teeth. Accordingly, currently available splitting techniques fail to adequately address difficulties associated with splitting the tips of toothbrush bristles and other bristles (bristles of mascara brushes) in which long splits are undesirable.

There still exists a need for a brush which provides multiple performance characteristics in a single brush like soft feel, desired styling, separation/combing, volumizing, curling and lengthening of eyelashes.

SUMMARY

Accordingly, the present disclosure provides a brush and its method of manufacturing, for applying a composition such as a cosmetic, a medicinal or a personal care composition. The composition may include a liquid, semi-liquid, creamy, paste-like or viscous material.

It is a further objective of the present disclosure to provide a brush for applying cosmetic composition such as mascara or the like, to eyelashes or eyebrows for providing multiple performance characteristics like soft feel, desired styling, separation/combing, volumizing, curling and lengthening of eyelashes.

According to an embodiment of the present disclosure, the brush comprises a plurality of bristles mounted on a core. The core is formed from a pair of wire segments which are intertwisted. The free ends of the core are connected to a rod. The plurality of bristles are secured between the pair of intertwisted wire segments such that opposed ends of each of the plurality of bristles extend radially from the core. Further, the brush is configured to be dipped in a container filled with a composition. At least some of the plurality of bristles have their opposed ends split into a plurality of fragments. The fragments of tips are curved in shape and extend radially away from the bristle's longitudinal axis.

According to an embodiment of the present disclosure, the plurality of bristles have a snow flake shape. However, in alternate embodiments, the plurality of bristles may have any other shape known in the art.

According to an aspect of the present disclosure, after mounting the plurality of bristles on the core, the plurality of bristles are shaped such that the tips of the plurality of bristles form a cylindrical envelope that conically narrows toward the distal end of the brush opposite the rod. However, in alternate embodiments, the plurality of bristles can be shaped into any other outer envelope shape known in the art. It is possible to make the brush of the present disclosure with any shape of envelope surface, e.g., straight, curved or the like.

According to a further aspect of the present disclosure, there is provided a method of manufacturing the brush. The method of manufacturing of the brush comprises a splitting stage followed by a spreading stage. In the splitting stage, a brush which has bristles with non-split tips is mounted on a splitting tool in order to split the tip of the plurality of bristles into a plurality of fragments. The plurality of bristles of the brush undergo a rotary splitting that acts on the tip of at least some of the plurality of bristles of the brush. The splitting tool comprises a plurality of splitting blades.

The splitting blade has a cylindrical portion and a claw shape portion. The claw shape portion comprises a curved portion with a pointed tip. However, in alternate embodiments, each of the plurality of splitting blades may be of any other shape known in the art. During the splitting stage, the claw shape portions of the plurality of the splitting blades acts on the tips of the plurality of bristles to split them into numerous fragments. The fragments on the ends of each of the plurality of bristles provide a soft feel when a mascara is applied on the eyelashes or eyebrows.

According to an embodiment of the present disclosure, in the splitting stage, the brush is rotated while the splitting tool remains stationary. The brush rotates about a longitudinal axis of the core in a first direction, for example the counterclockwise direction. The claw shape portion of each of the plurality of splitting blades acts on the tip of the plurality of bristles of the rotating brush. The action of each of the plurality of the splitting blades on the tip of the plurality of bristles leads to splitting of the tip of the plurality of bristles into numerous fragments. The speed of rotation of the brush is adjustable such that gradual splitting can be obtained, without heating up and melting the bristles, thus finely splitting the tip of the plurality of the bristles into numerous fragments.

However, in alternate embodiments, the brush may be rotated about any other axis than the longitudinal axis A-A of the core in a specific direction. In alternate embodiments, the brush may be rotated in a clockwise direction during splitting stage. However, in yet other alternate embodiments, the brush may remain stationary while the splitting tool may be rotated.

The splitting stage is then followed by a spreading stage which spreads out the split tip of the plurality of bristles by a spreading tool. The plurality of bristles of the brush undergo a rotary spreading that acts on the split tip of the plurality of bristles of the brush.

According to an aspect of the present disclosure, the spreading tool can exhibit the rotary motion and a linear motion.

The spreading of the split tip of each of the plurality of bristles enhances mascara holding capacity of the brush. The surface area of the plurality of bristles increases due to spread out of bristles which enhances its mascara holding capacity, better suited for combing and proper separation of the eyelashes, curling and lengthening of the eyelashes.

According to an embodiment of the present disclosure, the splitting and the spreading are done around the entire outer surface of the brush. However, in alternate embodiments, the splitting and the spreading may be done only on certain portions of the outer surface of the brush. For example, one side of the outer surface of the brush is split and spread while the other side of the outer surface of the brush may remain unsplit and unspread.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

FIG. 1 illustrates a brush comprising a plurality of bristles mounted on a core according to an embodiment of the present disclosure;

FIG. 2 shows a portion of the brush of FIG. 1 with the plurality of bristles before undergoing a process for splitting and spreading of tips of the bristles;

FIG. 3 illustrates an enlarged view of one of the plurality of bristles of the brush of FIG. 2;

FIG. 4 illustrates a simplified diagram of a splitting stage, leads to splitting of a tip of each of the plurality of bristles mounted on the core of the brush using a splitting tool according to an embodiment of the present disclosure;

FIG. 5 illustrates one of a plurality of splitting blades used in the splitting tool of FIG. 4;

FIG. 6 illustrates a tip of one of the plurality of bristles of the brush of FIG. 4 which has undergone the splitting stage;

FIG. 7 illustrates a simplified diagram of a spreading stage, that leads to spread out of the split tip of each of the plurality of bristles by a spreading tool according to the embodiment of the present disclosure;

FIG. 8 illustrates an arrangement of the brush and the spreading tool of FIG. 7; and

FIG. 9 illustrates a tip of one of the plurality of bristles of the brush which has undergone the spreading stage of FIG. 7.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

DETAILED DESCRIPTION

FIG. 1 shows an exemplary brush 24 according to a preferred embodiment of the present disclosure. The brush 24 is particularly a mascara brush for applying mascara to the eyelashes. The brush 24 comprises a plurality of bristles 30 mounted on a core 20. The core 20 is formed from a pair of wire segments which are intertwisted together. The free ends (not visible) of the core 20 are connected to the rod 25. The plurality of bristles 30 are secured between the pair of intertwisted wire segments such that opposite ends of each of the plurality of bristles 30 extend radially from the core 20 to form a helical array. Further, the brush 24 is configured to be dipped in a container (not shown) filled with a composition. As seen in FIG. 1, at least a few of bristles 30 have tips that are axially split into more than two spread out fragments. The fragments of the tips of the bristles 30 have a curved shape and extend radially away from the bristle's longitudinal axis, see FIG. 9.

FIG. 2 shows a portion of the brush 24 with bristles 30 before undergoing a process for splitting and spreading of the tips of the bristles 30.

FIG. 3 illustrates an enlarged view of one of the plurality of bristles 30 of the brush 24 of FIG. 2. The plurality of bristles 30 have a snow flake shape according to a preferred embodiment of the present disclosure. However, in alternate embodiments, the plurality of bristles 30 may be of any other shape known in the art.

According to an embodiment of the present disclosure, after mounting the plurality of bristles 30 on the core 20, the plurality of bristles 30 are shaped. In the example of FIG. 4, the plurality of bristles 30 are shaped such that the tips of the plurality of bristles 30 form a cylindrical envelope 31 that conically narrows toward the distal end 40 of the brush 24 opposite the rod 25. However, in alternate embodiments, the plurality of bristles 30 can be shaped to achieve any other outer envelope shape known in the art. It is possible to make the brush 24 of the present disclosure with any shape of envelope surfaces e.g. straight, curved or the like.

According to present embodiment, the above mentioned shapes can be achieved by cutting. However, in alternate embodiments, the above mentioned shapes may be achieved by any other method known in the art.

With reference to FIGS. 4, 5, 6, 7, 8 and 9, there is provided a method of manufacturing the brush 24 of present disclosure. The method of manufacturing of the brush 24 comprises a splitting stage followed by a spreading stage. In the splitting stage, a brush 24 which has bristles 30 with non-split tips, is mounted adjacent a splitting tool 50 as shown in FIG. 4, in order to split the tip of each of the plurality of bristles 30 into numerous fragments. The splitting tool 50 comprises a plurality of splitting blades 60. The plurality of bristles 30 of the brush 24 undergoes a rotary splitting via contact with the splitting blades 60. This rotary splitting acts on the tip of each of the plurality of bristles 30 of the brush 24.

FIG. 5 illustrates one of the plurality of splitting blades 60 used in the splitting tool 50 of FIG. 4 in isolation. As shown, the splitting blade 60 has a cylindrical portion 59 and a claw shape portion 61. The claw shape portion 61 comprises a curved portion 62 with a pointed tip 63. However, in alternate embodiments, each of the plurality of splitting blade 60 may be of any other shape known in the art.

According to an embodiment of the present disclosure, in the splitting stage, the brush 24 is rotated while the splitting tool 50 remains stationary. The brush 24 rotates about a longitudinal axis A-A′ (refer FIG. 4) of the core 20 in a specific direction, for example the counterclockwise direction as represented by an arrow 5 in FIG. 5. The claw shape portions 61 of the plurality of splitting blades 60 acts on the tips of the plurality of bristles 30 of the rotating brush 24 to split them into numerous fragments. The speed of rotation of the brush 24 is adjustable. Gradual splitting is thereby obtained, without heating up and melting the bristles, thus finely splitting the tip of each of the plurality of the bristles 30 into numerous fragments. The amount of time the bristles contact the splitting blade 60 as well as the rotational speed will depend on the physical properties of the bristles such as the material of the bristles, the shape of the bristles, the thickness of the bristles, etc. One skilled in the art will be able to adjust the settings to arrive at the desired splitting of the bristle ends.

However, in alternate embodiments, the brush 24 may be rotated about a different axis other than the longitudinal axis A-A of the core 20. In alternate embodiments, the brush 24 may also be rotated in a clockwise direction during the splitting stage. However, in yet other alternate embodiments, the brush 24 may remain stationary while the splitting tool 50 may be rotated in a specific direction around the tips of the bristles.

FIG. 6 shows one of the plurality of bristles 30 in isolation with the fragments 70 on its tip, formed by the action of the claw shape portion 61 of one of the plurality of the splitting blades 60. The fragments 70 on tip of each of the plurality of bristles 30 provide a soft end for applying mascara to the eyelashes or eyebrows.

As noted above, the splitting parameters, such as the dimension of each of the plurality of splitting blades 60, the splitting time and splitting pressure, are chosen as a function of the type of fragments 70 which are desired to be obtained.

According to an embodiment of the present disclosure, when the splitting is applied to the tip of each of the plurality of bristles 30, the resulting brush 24 will be of a type that can be used for volumizing, but with soft bristle tips. However, in alternate embodiments, splitting may be applied to an entire length of each of the plurality of bristles 30 that extends from the core 20. The resulting brush 24 will have a softer feel as a substantial portion of each of the plurality of bristles 30 will have been split. However, the portion of each of the plurality of bristles 30 gripped by the intertwisted wire portion of the core 20 will usually remain intact and unaffected by the splitting process.

FIG. 7 illustrates a spreading stage which causes spread out of the split tip of each of the plurality of bristles 30 by a spreading tool 80. Once the tips of the plurality of bristles 30 of the brush 24 have undergone splitting (as explained with reference to FIGS. 4 and 5), the brush 24 is further mounted adjacent a spreading tool 80 so as to spread out the split tip of each of the plurality of bristles 30 of the brush 24. The plurality of bristles 30 of the brush 24 undergoes a rotary spreading that acts on the split tip of each of the plurality of bristles 30 of the brush 24.

According to an embodiment of the present disclosure, the spreading tool 80 comprises a metal brush. However, in alternate embodiments, the spreading tool 80 may comprise a non-metallic brush, an abrasive surface or any material that can cause the split tips to spread out without removal of the split tips from the ends of the bristles.

As shown in FIG. 8, the brush 24 is rotated about the longitudinal axis A-A′ (refer FIG. 7) of the core 20 in a first direction, for example the counterclockwise direction as represented by an arrow 6. The spreading tool 80 acts on the split tip of each of the plurality of the bristles 30 while rotating about its axis, parallel to the longitudinal axis A-A′of the core 20, in a second direction opposite to that of the rotation direction of the brush 24, e.g., in the clockwise direction as represented by an arrow 7 in FIG. 8.

However, in alternate embodiments, the brush 24 may be rotated about any other axis than the longitudinal axis A-A of the core 20 and/or in a different direction, for example the clockwise direction, and the spreading tool 80 may be rotated about any other axis and/or in a different direction (substantially opposite to direction of rotation of the brush 24), for example the counterclockwise direction.

Further, as shown in FIG. 7, the spreading tool 80 not only exhibits the rotary motion as represented by the arrow 7 in FIG. 8, but also preferably exhibits a linear motion as shown by an arrow 75 in FIG. 7.

According to an embodiment of the present disclosure, the linear motion of the spreading tool is a continuous motion for spreading out of the split tip of each of the plurality of bristles 30. In alternate embodiments, the linear motion of the spreading tool may be a non-continuous motion for spreading out of the split tip of each of the plurality of bristles 30.

According to an alternate embodiment, the brush 24 may exhibit the rotary motion and the linear motion while the spreading tool 80 may exhibit only the rotary motion.

Adjusting the speed of rotation of the brush 24 and/or of the spreading tool 80 will alter the amount of the spreading to different values. Gradual spreading can thereby be obtained, without heating up or melting the tips of the bristles, thus finely spreading the split tip of each of the plurality of bristles 30.

FIG. 9 shows one of the plurality of bristles 30 in isolation with the spread out fragments 70 on its tip, formed by the action of the spreading tool 80 on one of the plurality of the bristles 30. The spread out fragments 70 on tip of each of the plurality of bristles 30 provide a brush having enhanced mascara holding capacity and better combing and separation of eyelashes or eyebrows when the mascara is applied on the eyelashes or eyebrows.

The spreading parameters, such as the dimension of the spreading tool 80, the spreading time and spreading pressure, are chosen as a function of the type of spread out fragments 70 which are desired to be obtained.

The spreading of the split tip of each of the plurality of bristles 30 enhances mascara holding capacity of the brush 24. The surface area of the plurality of bristles 30 increases due to spread out of bristles 30 which enhances its mascara holding capacity, better suited for combing and proper separation of the eyelashes, curling and lengthening of the eyelashes.

According to an embodiment of the present disclosure, the plurality of bristles 30 are solid in cross-section at least at their tips. However, in alternate embodiments, the plurality of bristles 30 may be hollow in cross-section, and preferably along their entire length. In alternate embodiments, only some of bristles of the plurality of bristles 30 may be hollow in cross section while some may be solid in cross section.

According to an embodiment of the present disclosure, the plurality of bristles 30 may or may not have longitudinal voids or grooves.

According to an embodiment of the present disclosure, the splitting and the spreading are done around the entire outer surface of the brush 24. However, in alternate embodiments, the splitting and the spreading may be done only on some portions of the outer surface of the brush 24. For example, one side of the outer surface of the brush 24 is split and spread while the other side of the outer surface of the brush 24 may remain unsplit and unspread.

According to an embodiment of the present disclosure, the brush 24 is driven by a continuous rotating movement about its axis A-A′. However, in alternate embodiments, the brush 24 may be driven by a non-continuous rotating movement about its axis A-A′.

According to an embodiment of the present disclosure, the core 20 is centered. However, in alternate embodiments, the core 20 may be off-centered.

According to an embodiment of the present disclosure, the plurality of bristles 30 of the brush 24 do not vary in properties such as material, shape, length, cross-section, diameter, thickness, length, color or likewise. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may vary in properties such as material, shape, length, cross-section, diameter, thickness, length, color or likewise.

According to a preferred embodiment of the present disclosure, the plurality of bristles 30 of the brush 24 have a snowflake shape. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may be of a shape selected from tubular, circular, round, oval, square, rectangular, polygonal or any another shape known in the art.

According to an embodiment of the present disclosure, the plurality of bristles 30 of the brush 24 are rectilinear. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may have an undulating shape, or any another known shape.

According to an embodiment of the present disclosure, the diameter of each of the plurality of bristles 30 of the brush 24 is same. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may be have varying diameters.

According to an embodiment of the present disclosure, thickness of each of the plurality of bristles 30 of the brush 24 may be same. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may have varying thicknesses.

According to an embodiment of the present disclosure, the color of each of the plurality of bristles 30 of the brush 24 may be same. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may have varying colors. The colors used may be chromatic or non-chromatic. They may also be contrasting colors, without one necessarily being chromatic.

According to an embodiment of the present disclosure, the plurality of bristles 30 of the brush 24 may be of animal origin or synthetic origin, for example made from nylon or polyester. However, in alternate embodiments, the plurality of bristles 30 may be of natural origin or may be used in a mixture with synthetic bristles.

According to an embodiment of the present disclosure, material of each of the plurality of bristles 30 of the brush 24 may be same. However, in alternate embodiments, the plurality of bristles 30 of the brush 24 may be made of different materials. The bristles may comprise any suitable material, e.g., thermoplastics such as polyethylene, polypropylene, polyethylene terephthalate (PET), polyoxymethylene (POM), polyamide (PA), polystyrene (PS), or nylon. The material of the bristles is not limited.

Although, the present disclosure has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It is therefore to be understood that numerous modifications may be made to the embodiments and that other arrangements may be devised. 

What is claimed is:
 1. A brush, comprising: an intertwisted wire core defining a longitudinal axis; and a plurality of bristles secured within the intertwisted wire core, each of the plurality of bristles having opposed ends that extend radially away from the core, and at least some of the opposed ends of the plurality of bristles being split into a plurality of fragments.
 2. The brush of claim 1, wherein each of the plurality of bristles has a cross sectional snowflake shape.
 3. The brush of claim 1, wherein the plurality of bristles form a cylindrical envelope along the longitudinal axis of the intertwisted wire core.
 4. The brush of claim 1, wherein a length of the bristles decrease toward a distal end of the core so as to form a conical shape.
 5. The brush of claim 1, further comprising a rod attached to an end of the intertwisted wire core.
 6. A method of manufacturing a brush, the method comprising: mounting a bush adjacent a splitting tool having a plurality of blades, the brush having an intertwisted wire core defining a longitudinal axis, and a plurality of bristles secured within the intertwisted wire core, each of the plurality of bristles having opposed ends that extend radially away from the core; rotating the brush relative to the splitting tool; contacting at least some of the opposed ends of the plurality of bristles with the plurality of blades of the splitting tool so as to split the at least some of the opposed ends of the plurality of bristles into a plurality of fragments.
 7. The method of claim 6, wherein each of the plurality of blades has a claw shape with a curved portion and a pointed tip.
 8. The method of claim 6, wherein the brush is rotated along the longitudinal axis.
 9. The method of claim 6, further comprising rotating the splitting tool along a longitudinal axis thereof parallel to the longitudinal axis of the brush.
 10. The method of claim 6, wherein all of the opposed ends of the plurality of bristles are split into the plurality of fragments.
 11. The method of claim 6, further comprising: mounting the bush adjacent a spreading tool having an abrasive surface; rotating the brush relative to the spreading tool; contacting the abrasive surface of the spreading tool with the plurality of fragments at the at least some of the opposed ends of the plurality of bristles such that the plurality of fragments are spread apart.
 12. The method of claim 11, wherein a surface area corresponding to of each of the plurality of fragments is increased when the plurality of fragments are spread apart.
 13. The method of claim 11, further comprising moving the spreading tool linearly along the longitudinal axis of the spreading tool while the plurality of fragments are spread apart. 